Patent Application
20250146271
The present disclosure relates generally to exterior wall assemblies and, more specifically, to exterior wall system assemblies and exterior wall system component subassemblies with drainage and fireblocking features.
In modern construction, exterior wall assemblies are often made of multiple layers and components that provide various desired performance characteristics to the wall assemblies. Water and moisture can accumulate between the layers of the exterior wall assemblies, potentially leading to degradation of the wall components.
In light of recent incidents of deadly fires within multi-story buildings, there is a renewed emphasis on limiting fire propagation through internal void spaces found in exterior wall assemblies. Current systems for limiting fire propagation often do not account for the need for moisture management in modern exterior wall assembly construction.
Thus, there is a need for exterior wall assemblies that can address both fire propagation risk management and moisture management more effectively than current technology.
The present disclosure encompasses exterior wall system assemblies, exterior wall system component subassemblies and/or exterior wall system components with drainage and fireblocking features.
The present disclosure encompasses an exterior wall system component subassembly comprising: a wedge comprising a bottom side, a top side aligned oblique to the bottom side, a rear side extending between the bottom side and the top side, wherein the top side comprises a top front edge and a top rear edge; a fireblocking base form aligned below the wedge, wherein the fireblocking base form comprises a fire-resistant material; and, a channel disposed on the top side of the wedge, wherein the channel comprises a channel outlet, and wherein the channel outlet is aligned proximal to the top front edge and distal to the top rear edge.
In one aspect, the exterior wall system component subassembly can comprise a waterproof membrane aligned on the top side of the wedge. In another aspect, the channel can comprise the waterproof membrane. In a further aspect, the exterior wall system component subassembly can comprise a weep tube aligned on the top side of the wedge, and wherein the weep tube is in fluid communication with the channel. In yet another aspect, the fireblocking base form can comprise a base form front side, a base form rear side spaced apart from and opposing the base form front side, a base form bottom side extending between the base form front side and the base form rear side, a base form top side extending between the base form front side and the base form rear side, a base form first side extending between the base form front side and the base form rear side and the base form bottom side and the base form top side, and a base form second side extending between the base form front side and the base form rear side and the base form bottom side and the base form top side. In still a further aspect, the wedge can be disposed on the base form top side. In one aspect, the wedge can comprise a front side extending between the bottom side and the top side, and wherein the front side of the wedge can be aligned coplanar with the base form front side. In another aspect, the fire-resistant material can comprise a lamella. In a further aspect, the lamella can comprise a plurality of lamellar layers aligned transverse to the base form front side. In yet another aspect, the fire-resistant material can comprise a mineral wool. In still a further aspect, the channel can comprise a first water-resistant ribbon and a second water-resistant ribbon, wherein the first water-resistant ribbon and the second water resistant ribbon are disposed on the waterproof membrane. In one aspect, the wedge, the channel and the fireblocking base form can be disposed in an exterior wall panel, wherein the wall panel can comprise a support frame and a front face, wherein the wedge and the fireblocking base form can be mounted to the support frame and disposed intermediate between the support frame and the front face, wherein wall panel can comprise a weep hole defined in the front face, and wherein the channel can be in fluid communication with the weep hole. In another aspect, the wedge can comprise the fire-resistant material.
The present disclosure also encompasses an exterior wall system component subassembly comprising: a wedge comprising a front side, a rear side opposing the front side, a bottom side extending between the front side and the rear side, and a top side aligned oblique to the front side, wherein the top side and the rear side cooperate to form a top rear edge, and wherein the top side and the front side cooperate to form a top front edge; a plurality of channels aligned on the top side of the wedge, and wherein each channel of the plurality of channels comprises a channel outlet aligned distal to the top rear edge and proximal to the top front edge; and, a fireblocking base form comprising a base form front side, a base form rear side spaced apart from and opposing the base form front side, a base form bottom side extending between the base form front side and the base form rear side, a base form top side extending between the base form front side and the base form rear side, a base form first side extending between the base form front side and the base form rear side and the base form bottom side and the base form top side, and a base form second side extending between the base form front side and the base form rear side and the base form bottom side and the base form top side, wherein the fireblocking base form comprises a fire-resistant material, and wherein the wedge is disposed on the base form top side. In one aspect, the exterior wall system component subassembly can comprise a waterproof membrane aligned on the top side of the wedge. In another aspect, each channel of the plurality of channels can comprise a first water-resistant ribbon, a second water-resistant ribbon, and the waterproof membrane. In a further aspect, the exterior wall system component subassembly can comprise a plurality of weep tubes aligned on the top side of the wedge, and wherein each weep tube of the plurality of weep tubes can be in fluid communication with a channel of the plurality of channels. In yet another aspect, the fire-resistant material can comprise a lamella. In still a further aspect, the lamella can comprise a plurality of lamellar layers aligned transverse to the base form front side. In one aspect, the fire-resistant material can comprise a mineral wool. In another aspect, the wedge can comprise the fire-resistant material.
The present disclosure also encompasses an exterior wall system component subassembly comprising: a wedge comprising a front side, a rear side spaced apart from the front side, a bottom side extending between the front side and the rear side, a top side extending between the front side and the rear side, wherein the top side is aligned oblique to the front side, wherein the top side and the front side cooperate to form a top front edge, wherein the top side and the rear side cooperate to form a top rear edge; a fireblocking base form aligned below the wedge, wherein the fireblocking base form comprises a base form front side, a base form rear side spaced apart from and opposing the base form front side, a base form bottom side extending between the base form front side and the base form rear side, a base form top side extending between the base form front side and the base form rear side, a base form first side extending between the base form front side and the base form rear side and the base form bottom side and the base form top side, a base form second side extending between the base form front side and the base form rear side and the base form bottom side and the base form top side, and wherein the fireblocking base form comprises a fire-resistant material; and, a waterproof membrane aligned on the top side of the wedge; a plurality of channels aligned on the top side of the wedge, wherein each channel of the plurality of channels comprises the waterproof membrane, a first water-resistant ribbon aligned on the waterproof membrane, and a second water-resistant ribbon on the waterproof membrane, wherein the first water-resistant ribbon extends from a first water-resistant ribbon end to a first water-resistant ribbon apex, wherein the second water-resistant ribbon extends from a second water-resistant ribbon end to a second water-resistant ribbon apex, wherein the first water-resistant end is spaced apart from the second water resistant end, wherein the first water-resistant end and the second water-resistant end cooperate to form a channel outlet, and wherein the channel outlet is aligned distal to the top rear edge and proximal to the top front edge of the wedge.
These and other aspects are set forth in greater detail below and in the drawings for which a brief description is provided as follows.
The present disclosure encompasses exterior wall system assemblies, wall system component subassemblies, and wall system components that include drainage features for addressing the accumulation of moisture within air cavities or interior void spaces of exterior wall assemblies and fireblocking features for inhibiting and/or preventing the migration of fire through interior void spaces in exterior wall assemblies. The present disclosure encompasses exterior wall system assemblies that are assembled on-site, also known as field installation, exterior wall system assemblies assembled from prefabricated components and component subassemblies that include drainage features or combinations of drainage features and fireblocking features, exterior wall system component subassemblies that are field installed and include combinations of both fireblocking and drainage features, prefabricated exterior wall system components and component subassemblies that include combinations of both fireblocking and drainage features.
The present disclosure also encompasses exterior wall system assemblies that comprise one or more components having drainage features and a fireblocking framework composed of fireblocking rows and/or intersecting fireblocking columns. The fireblocking columns and fireblocking rows are composed of fireblocking vertical forms and fireblocking base forms, respectively, each of which comprises fire-resistant material provided in a lamella comprising a plurality of lamellar layers aligned transverse to the front face of the wall. The fireblocking base forms can comprise a top side that is aligned perpendicular to the front face of the exterior wall system assembly or a top side that is sloped downward from the interior of the wall assembly to the front face of the wall so as to allow moisture that collects within the concealed spaces of the wall assembly to migrate out through channels and/or tubes disposed within the wall assembly and that open to the outside of the front face of the wall. Wall system component subassemblies comprising a fireblocking base form with a top side aligned perpendicular to a front face of an exterior wall system assembly can also include a wedge disposed atop and/or superior to the fireblocking base form, the wedge comprising a sloped wedge top side and a plurality of drainage channels formed by a plurality of ribbons disposed on a waterproof membrane that is disposed on the wedge top side.
As used herein, the term “wedge” refers to an object with a body having a top side, a bottom side, opposing the top side, a rear side extending between the top side and the bottom side, a front side opposing the rear side and extending between the top side and the bottom side, wherein the rear side height is greater than the front side height, and wherein the top side is aligned oblique to the bottom side, the rear side and the front side. The body of a wedge has an acute angle formed between the rear side and the top side and an obtuse angle formed between the top side and the front side.
As used herein, the term “oblique” refers to an alignment of one surface or structure that is non-parallel and non-perpendicular to another surface or structure.
As used herein, the term “obtuse” refers to an angle or alignment that is greater than 90° and less than 180°.
As used herein, the term “acute” refers to an angle or alignment that is greater than 0° and less than 90°.
As used herein, the term “air cavity” refers to a void space between two layers of material intentionally included within a wall assembly for the movement of water.
As used herein, the term “concealed space” refers to an enclosed space within a partition, a floor, a roof, a set of stairs, a furring, a pipe chase, a column, and/or an external wall assembly. A concealed space can encompass one or more air cavities and/or internal void spaces that are not interrupted by a firebreak.
As used herein, the term “fireblocking” refers to a material that resists the free passage of flame and/or hot gasses through a building through concealed spaces. Examples of fireblocking materials include, but are not limited to, two-inch (50.8 mm) nominal lumber, two thicknesses of one-inch (25.4 mm) nominal lumber with broken lap joints, one thickness of 0.719-inch (18.3 mm) wood structural panel with joints backed by 0719-inch (18.3 mm) wood structural panels, one thickness of 0.75-inch (19.1 mm) particleboard with joints backed by 0.75-inch (19.1 mm) particleboard, one-half inch (12.7 mm) gypsum board, one-fourth inch (6.4 mm) cement-based millboard, batts, blocks or blankets of mineral wool and/or mineral fiber.
As used herein, the term “non-combustible” refers to (i) a material no part of which will ignite and burn when subjected to fire and/or a material passing ASTM E136-22; or (ii) a material having a structural base as defined in (i) with a surfacing material of not greater than one-eighth of an inch (3.2 mm) thickness which has a flame-spread index of 50 or less.
As used herein, the term “fire-resistant” refers to a material that is considered “non-combustible” and/or a “fireblocking” material and/or otherwise tends to resist combustion when exposed to fire or a source of ignition.
As used herein, the term “water-resistant” refers to a material or object that tends to inhibit or to prevent water migrating therethrough or penetrating therein under atmospheric conditions.
As used herein, the term “waterproof” refers to a material or object that is generally impermeable to water under atmospheric conditions.
As used herein, the term “aligned on” refers to a material or object being directly or indirectly situated above another material or object with either no or one or more materials or objects situated therebetween.
As used herein, the term “anterior” refers to being situated in front of a part or toward the front and/or outer face of an exterior wall system assembly, and the term “posterior” refers to being situated behind a part or toward the rear and/or interior of the exterior wall system assembly. As used herein, the term “superior” refers to being situated higher up or toward the roof of the structure upon which the wall assembly is mounted, and the term “inferior” refers to being situated below a part or closer to the base of the structure upon which the wall assembly is mounted.
A waterproof membrane 122 is disposed directly or indirectly on the wedge top side 121. The waterproof membrane 122 is composed of a waterproof composition that generally prevents penetration of water therethrough at atmospheric pressure. The waterproof membrane 122 can cover the entirety of the wedge top side 121 or a portion thereof. The waterproof membrane 122 covers the wedge top side 121 and extends between the wedge top rear edge 156 to the wedge top front edge 158 and between the wedge first side 157 and the wedge second side 153.
A plurality of channels 162 is aligned on the wedge top side 121. Each channel 162 of the plurality of channels is bounded by the waterproof membrane 122, which forms the floor of each channel 162, a first water-resistant ribbon 166, and a second water-resistant ribbon 168. Each first ribbon 166 and each second ribbon 168 of each channel 162 separately forms a sidewall of the channel 162. Each channel 162 is open to the wedge top rear edge 156. Each first ribbon 166 of each channel 162 extends from a first water-resistant ribbon end 172, disposed at the wedge top front edge 158, to a first water-resistant ribbon apex 170 disposed at the wedge top rear edge 156. Each second ribbon 168 of each channel 162 extends from a second water-resistant ribbon end 173, disposed at the wedge top front edge 158, to a second water-resistant ribbon apex 170 disposed at the wedge top rear edge 156. A first water-resistant ribbon 166 of one channel 162 can connect to a second water-resistant ribbon 168 of an adjacent channel 162 at a water-resistant ribbon apex 170. Each first ribbon end 172 of each channel 162 is spaced apart from each second ribbon end 173 of the channel 162, thereby forming a channel outlet 164 therebetween. Each first ribbon 166 of each channel 162 is disposed at an angle and oblique to the second water-resistant ribbon 168 of the respective channel 162. Accordingly, the sidewalls of each channel 162 extend from two adjacent apexes 170. The first and second apexes 170 of each channel 162 are spaced farther apart than the first and second ribbon ends 172 and 173, respectively, of the channel 162. Each channel 162 exhibits an apex width as measured proximal to the wedge top rear edge 156 and an outlet width measured proximal to the wedge top front edge 158. The apex width of each channel 162 is greater than the outlet width of the channel 162. Thus, the side walls of each channel 162 are angled toward the channel outlet 164. Water that collects within a wall system assembly can migrate down the inclined surface of the wedge top side 121 and can be directed by the side walls of the channels 162 to the channel outlets 164. The first water-resistant ribbons 166 and the second water-resistant ribbons 168 are formed of a water-resistant material that prevents or inhibits the migration of water therethrough under atmospheric pressure.
The insulation layer 350 is aligned above the wedge 106 in the exterior wall system assembly 100. A water-resistant layer 323 is applied to the substrate 315, and vertical ribbons of an adhesive layer 325 are disposed on the water-resistant layer 323. The insulation layer 350 is mounted to the substrate 315 by adherence provided by the vertical ribbons of the adhesive layer 325. The bottom side 378 of the insulation layer 350 is cut at an angle so that the front bottom edge of the insulation layer 350 is lower than the rear bottom edge of thereof. The angle of the bottom side 378 of the adhesive layer is generally equal to the angle of the wedge top side 121. An arcuate channel 377 is formed in the bottom side 378 and extends from the rear bottom edge to the front bottom edge of the insulation layer 350. The arcuate channel 377 is aligned with the channel outlet 164 of the channel 162 with which the arcuate channel 377 cooperates. The weep hole 140 is the front end of the arcuate channel 377. The arcuate channel 377 provides a portion of a ceiling for the channel 162 for water migrating through a channel 162 to the front face of the exterior wall system assembly 100. Water can drain down the vertical section of the wall assembly between the ribbons of adhesive layer 325 to the channels 162 and then can drain down through the channels 162 to the weep holes 140 and out of the exterior wall system assembly 100 to the outer face thereof.
The exterior wall system assembly 300 also comprises one or more weep hole rows 344, each of which comprises a plurality of weep holes 340. The weep hole rows 344 are aligned proximal to the fireblocking base forms 306. More particularly, each weep hole 340 is aligned proximal to the top front edge 258 of a fireblocking base form 306. Each fireblocking base form 306 can abut at least one fireblocking vertical form 304 on the left side 251 and/or the right side 253 of the fireblocking base form 306. Likewise, each fireblocking vertical form 304 can abut at least one fireblocking base form 306 on the left side and/or the right side of the fireblocking vertical form 304.
The exterior wall system assembly 300 also includes insulation layers 350 disposed above and below the fireblocking base form 306. The insulation layers 350 can be formed of any appropriate material, such as expanded polystyrene (EPS), extruded polystyrene (XPS), graphite polystyrene (GPS), rock wool, and/or mineral wool or another material having insulative properties and other desired performance characteristics. The insulation layer 350 is mounted to a sheathing layer 315 by an adhesive and basecoat layer 376. The adhesive and base coat layer 376 can be provided in a plurality of vertical strips on an air and water-resistant layer covering the sheathing layer 315. One or more concealed spaces can be formed by the cooperation of the adhesive and base coat layer 376, the air and water-resistant layer and the insulation layer 350. These concealed spaces potentially could serve as a route through which fire could propagate vertically and/or horizontally through the exterior wall system assembly 300.
The fire-resistant material of each fireblocking vertical form 304 contacts the fire-resistant material of each adjacently aligned fireblocking base form 306 and each adjacently aligned fireblocking vertical form 304 contacting the respective fireblocking vertical form 304, thereby forming the fireblocking framework 312 that forms a continuous multi-layer fire-resistant barrier between and throughout each story of a multi-story building.
In one aspect, each fireblocking base form 306 can be aligned a distance in a range of about 2.438 m to about 6.096 m from the nearest adjacent row of fireblocking base forms 306 above and/or below. In another aspect, each row of fireblocking base forms 306 can be aligned a distance in a range of about 3 m to about 6 m from the nearest adjacent row of fireblocking base form 306 above and/or below. In a further aspect, each row of fireblocking base forms 306 can be aligned a distance of less than or equal to about 6 m from the nearest adjacent row of fireblocking base forms 306 above or below. In yet another aspect, each fireblocking vertical form 304 can be aligned a distance in a range of about 2.438 m to about 6.096 m from the nearest adjacent fireblocking vertical form 304 to the left and/or right. In another aspect, each fireblocking vertical form 304 can be aligned a distance in a range of about 3 m to about 6 m from the nearest adjacent fireblocking columns 306 to the left and/or right. In a further aspect, each fireblocking vertical form 304 can be aligned a distance of less than or equal to about 6 m from the nearest adjacent fireblocking vertical form 304 to the left and/or right. In still a further aspect, the exterior wall system assembly 300 can comprise one or more concealed spaces each with an area bounded by one or more fireblocking vertical forms 304 and one or more fireblocking base forms 306 of less than about 9.3 m2. In another aspect, the exterior wall system assembly 300 can comprise one or more concealed spaces each which is disposed within an area 303 bounded by one or more fireblocking vertical forms 304 and one or more fireblocking base forms 306 in a range of about 4 m2 to about 9 m2.
The fireblocking base form 306 comprises a fire-resistant material 375, such as, for example, mineral wool that is provided in a plurality of lamellar layers to form a lamella 347. The lamellar layers of the lamella 347 are aligned generally perpendicular to a front face of the exterior wall system assembly 300. On the top side of the fireblocking base form 306 is disposed the wedge 320. The wedge 320 comprises a wedge front side 359 and a wedge rear side 354 spaced apart from and opposing the wedge front side 359. The wedge rear side 354 can be aligned generally parallel to the wedge front side 359. The wedge front side 359 exhibits a wedge front side height, and the wedge rear side 354 exhibits a wedge rear side height. The wedge rear side height is greater than the wedge front side height. A wedge bottom side 355 extends between the wedge front side 359 and the wedge rear side 354. The wedge bottom side 355 can be aligned perpendicular to the wedge front side 359 and/or the wedge rear side 354. The wedge bottom side 355 can be disposed on the top side of the fireblocking base form 306. The wedge 320 also includes a wedge top side 321 that is aligned non-parallel and/or oblique to the wedge bottom side 355 and is sloped and/or inclined downward from a wedge top rear edge 356 to a wedge top front edge 358. A wedge first side 357 extends between the wedge rear side 354 to the wedge front side 359, and a wedge second side 353 is opposed to the wedge first side 357 and extends between the wedge rear side 354 to the wedge front side 359.
A waterproof membrane 322 is disposed on the wedge top side 321. The waterproof membrane 322 covers the wedge top side 321 and extends between the wedge top rear edge 356 to the wedge top front edge 358 and between the wedge first side 357 to the wedge second side 353. A plurality of channels is aligned on the wedge top side 321. Each channel 362 of the plurality of channels is bounded by the waterproof membrane 322, which forms the floor of each channel 362, a first water-resistant ribbon 366, and a second water-resistant ribbon 368. Each of the first water-resistant ribbon 366 and the second water-resistant ribbon 368 of each channel 362 forms a sidewall of the channel 362. Each first ribbon 366 of each channel 362 extends from a first water-resistant ribbon end 372 disposed at the wedge top front edge 358 to a first water-resistant ribbon apex 370 disposed at the wedge top rear edge 356. Each second ribbon 368 of each channel 362 extends from a second water-resistant ribbon end 371 disposed at the wedge top front edge 358 to a second water-resistant ribbon apex 370 disposed at the wedge top rear edge 356. Each first ribbon end 372 of each channel 362 is spaced apart from each second ribbon end 371 of the channel 362, thereby forming a channel outlet 364 therebetween. Each first ribbon 366 of each channel 362 is disposed at an angle to the second water-resistant ribbon 368 of the respective channel 362. The angle of inclination between the first water-resistant ribbon 266 and the second water-resistant ribbon 368 can be oblique, acute, or a right angle. Accordingly, each first water-resistant ribbon apex 370 of each channel 362 is spaced apart from each second water-resistant ribbon apex 370 of the channel 362. The first and second apexes 370 of each channel 362 are spaced farther apart than the first and second ribbon ends 372 and 371 of the channel 362. Each channel 362 has an apex width proximal to the wedge top rear edge 356 and an outlet width proximal to the wedge top front edge 358. The apex width of each channel 362 is greater than the outlet width of the channel 362. Thus, the side walls of each channel 362 are angled toward the channel outlet 364. Water migrating down the sloped surface of the wedge top side 321 is directed by the side walls of the channels 362 to the channel outlets 364.
The fireblocking base form 306 is rectangular in configuration with a base form front side 301, a base form rear side 311 opposing the base form front side 301, a base form top side 307 extending between the base form front side 301 and the base form rear side 311, and a base form bottom side 305 opposing the base form top side 307 and extending between the base form front side 301 and the base form rear side 311. The base form rear side 311 can be aligned generally parallel to the base form front side 301, and the base form bottom side 305 can be aligned generally parallel to the base form top side 307. The fireblocking base form 306 also includes a fireblocking base form first side 308 extending between the fireblocking base form front side 301 and the fireblocking base form rear side 311 and the fireblocking base form top side 307 and the fireblocking base form bottom side 305. The fireblocking base form 306 also includes a fireblocking base form second side 309 extending between the fireblocking base form front side 301 and the fireblocking base form rear side 311 and the fireblocking base form top side 307 and the fireblocking base form bottom side 305.
The fireblocking base form 306 comprises a fire-resistant material 375, such as, for example, mineral wool, rock wool, foamed concrete, cementitious material, or glass matting. Examples of fire-resistant material include THERMAFIBER® Mineral Wool CI-C SC18 Mineral Wool Insulation from Thermafiber, Inc. of Toledo, Ohio, USA, and the monolithic density version of FRONTROCK™ Stone Wool Insulation from ROCKWOOL® of Milton, Ontario, Canada. The fireblocking base form 306 comprises a lamella 347 of the fire-resistant material 375. The lamella 347 comprises a plurality of lamellar layers stacked upon each other to form the overall lamella 347. The lamellar layers are aligned generally perpendicular or transverse to the front side and generally parallel to the bottom side of the fireblocking base form 306. In one aspect, the fireblocking base form 306 can comprise the fire-resistant material 375. In another aspect, the fireblocking base form 306 can consist essentially of the fire-resistant material 375. In yet another aspect, the fireblocking base form 306 can consist of the fire-resistant material 375. In one aspect, the fireblocking base form 306 can comprise a lamella 347 of fire-resistant material 375. In another aspect, the fireblocking base form 306 can consist essentially of a lamella 347 of fire-resistant material 375. In a further aspect, the fireblocking base form 306 can consist of a lamella 347 of fire-resistant material 375.
A waterproof membrane 322 is disposed on the wedge top side 321. The waterproof membrane 322 covers the wedge top side 321 and extends between the wedge top rear edge 356 to the wedge top front edge 358 and between the wedge first side 357 to the wedge second side 353. A plurality of channels 462 is aligned on the wedge top side 321. Each channel 462 of the plurality of channels is bounded by the waterproof membrane 322, which forms the floor of each channel 462, a first water-resistant ribbon 466, and a second water-resistant ribbon 468. Each of the first water-resistant ribbon 466 and the second water-resistant ribbon 468 of each channel 462 forms a sidewall of the channel 462. Each first ribbon 466 of each channel 462 extends from a first water-resistant ribbon end 472 disposed intermediate between the wedge top front edge 458 and the wedge top rear edge 456 to a water-resistant ribbon apex 470 disposed at the wedge top rear edge 356. Each second ribbon 468 of each channel 462 extends from a second water-resistant ribbon end 471 disposed intermediate between the wedge top front edge 458 and the wedge top rear edge 356 and a water-resistant ribbon apex 470 disposed at the wedge top rear edge 356. Each first ribbon end 472 of each channel 462 is spaced apart from each second ribbon end 471 of the channel 462, thereby forming a channel outlet therebetween.
Each channel outlet is disposed at and in fluid communication with a top end 477 of a weep tube 469. The exterior wall system component subassembly 460 comprises a plurality of weep tubes 469. At least of a portion of each weep tube 469 is disposed on the wedge top side 321. As shown in
Each first ribbon 466 of each channel 462 is disposed at an angle to the second water-resistant ribbon 468 of the respective channel 462. The angle formed by the first water-resistant ribbon 466 and the second water-resistant ribbon 468 can be acute, obtuse or a right angle. The apexes 470 of each channel 462 are spaced farther apart than the first and second ribbon ends 472 and 471 of the channel 462. Each channel 462 has an apex width proximal to the wedge top rear edge 356 and an outlet width proximal to the weep tube 469. The apex width of each channel 462 is greater than the outlet width of the channel 462. Thus, the side walls of each channel 462 are angled toward the channel outlet 464. Water migrating down the sloped surface of the wedge top side 321 is directed by the side walls of the channels 462 to the channel outlets 364 and the top end 477 of the weep tube 469.
The insulation layer 350 is aligned above the wedge 320 in the exterior wall system assembly 300. A water-resistant layer 323 is applied to the substrate 315, and vertical ribbons of an adhesive layer 325 are disposed on the water-resistant layer 323. The insulation layer 350 is mounted to the substrate 315 by adherence provided by the vertical ribbons of the adhesive layer 325. The bottom side 378 is cut at an angle so that the front bottom edge of the insulation layer 350 is lower than the rear bottom edge of thereof. The angle of the bottom side 378 of the adhesive layer is generally equal to the angle of the wedge top side 321. An arcuate channel 377 is formed in the bottom side 378 and extends from the rear bottom edge to the front bottom edge of the insulation layer 350. The arcuate channel 377 is aligned with the channel 362 and the the channel outlet 364. The weep hole 340 is the front end of the arcuate channel 377. The arcuate channel 377 provides a portion of a ceiling for the channel 362 for water migrating through a channel 362 to the front face of the exterior wall system assembly 300.
A waterproof membrane 322 is disposed on the wedge top side 321. The waterproof membrane 322 covers the wedge top side 321 and extends between the wedge top rear edge 356 to the wedge top front edge 358 and between the wedge first side 357 to the wedge second side 353. A plurality of channels 562 is aligned on the wedge top side 321. Each channel 562 of the plurality of channels is bounded by the waterproof membrane 322, which forms the floor of each channel 562, a first water-resistant ribbon 566, and a second water-resistant ribbon 568. Each of the first water-resistant ribbon 566 and the second water-resistant ribbon 568 of each channel 562 forms a sidewall of the channel 562. Each first ribbon 566 of each channel 562 extends from a first water-resistant ribbon end 572 disposed at the wedge top front edge 358 to a first water-resistant ribbon apex 570 disposed intermediate between the wedge top rear edge 356 and the wedge top front edge 358. Each second ribbon 568 of each channel 562 extends from a second water-resistant ribbon end 571 disposed at the wedge top front edge 358 to a second water-resistant ribbon apex 570 disposed intermediate between the wedge top rear edge 356 and the wedge top front edge 358. Each first ribbon end 572 of each channel 562 is spaced apart from each second ribbon end 571 of the channel 562, thereby forming a channel outlet 564 therebetween. Each first ribbon 566 of each channel 562 is disposed at an angle to the second water-resistant ribbon 568 of the respective channel 562. The angle of alignment of the first water-resistant ribbon 566 and the second water-resistant ribbon 568 can be acute, obtuse, or a right angle. Accordingly, each first water-resistant ribbon apex 570 of each channel 562 is spaced apart from each second water-resistant ribbon apex 570 of the channel 562. The first and second apexes 570 of each channel 562 are spaced farther apart than the first and second ribbon ends 572 of the channel 562. Each channel 562 has an apex width proximal to the wedge top rear edge 356 and an outlet width proximal to the wedge top front edge 358. The apex width of each channel 562 is greater than the outlet width of the channel 562. Thus, the side walls of each channel 562 are angled toward the channel outlet 564. Water migrating down the sloped surface of the wedge top side 321 is directed by the side walls of the channels 562 to the channel outlets 564.
The wall system component subassembly 660 comprises a fireblocking base form 306 comprising a fire-resistant material 375 provided in a plurality of lamellar layers to form a lamella 347. On the top side of the fireblocking base form 306 is disposed the wedge 320. The wedge 320 can be disposed directly on the fireblocking base form 306 or have one or more other layers disposed therebetween. The wedge 320 comprises a wedge front side 359 and a wedge rear side 354 spaced apart from and opposing the wedge front side 359. The wedge rear side 354 can be aligned generally parallel to the wedge front side 359. The wedge front side 359 exhibits a wedge front side height, and the wedge rear side 354 exhibits a wedge rear side height. The wedge rear side height is greater than the wedge front side height. A wedge bottom side 355 extends between the wedge front side 359 and the wedge rear side 354. The wedge bottom side 355 can be aligned perpendicular to the wedge front side 359 and/or the wedge rear side 354. The wedge bottom side 355 can be disposed on the top side of the fireblocking base form 306. The wedge 320 also includes a wedge top side 321 that is aligned oblique to the wedge bottom side 355 and is sloped downward from a wedge top rear edge 356 to a wedge top front edge 358. A wedge first side 357 extends between the wedge rear side 354 to the wedge front side 359, and a wedge second side 353 is opposed to the wedge first side 357 and extends between the wedge rear side 354 to the wedge front side 359.
A waterproof membrane 322 is disposed on the wedge top side 321. The waterproof membrane 322 covers the wedge top side 321 and extends between the wedge top rear edge 356 to the wedge top front edge 358 and between the wedge first side 357 to the wedge second side 353. A plurality of channels 662 is aligned on the wedge top side 321. Each channel 662 of the plurality of channels is bounded by the waterproof membrane 322, which forms the floor of each channel 662, a first water-resistant ribbon 666, and a second water-resistant ribbon 668. Each of the first water-resistant ribbon 666 and the second water-resistant ribbon 668 of each channel 662 forms a sidewall of the channel 662. Each first ribbon 666 of each channel 662 extends from a first water-resistant ribbon end 672 disposed intermediate between the wedge top front edge 358 and the wedge top rear edge 356 to a first water-resistant ribbon apex 670 also disposed intermediate between the wedge top rear edge 356 and the wedge top front edge 358. Each second ribbon 668 of each channel 662 extends from a second water-resistant ribbon end 671 disposed intermediate between the wedge top front edge 358 and the wedge top rear edge 356 to a second water-resistant ribbon apex 670 also disposed intermediate between the wedge top rear edge 356 and the wedge top front edge 358. Each first ribbon end 672 of each channel 662 is spaced apart from each second ribbon end 671 of the channel 662, thereby forming a channel outlet 664 therebetween. Each first ribbon 666 of each channel 662 is disposed at an angle to the second water-resistant ribbon 668 of the respective channel 662. The angle of orientation of the first and second ribbons 666 and 668 can be acute, obtuse or a right angle. Accordingly, each first water-resistant ribbon apex 670 of each channel 662 is spaced apart from each second water-resistant ribbon apex 670 of the channel 662. The first and second apexes 670 of each channel 662 are spaced farther apart than the first and second ribbon ends 671 of the channel 662. Each channel 662 has an apex width proximal to the wedge top rear edge 356 and an outlet width proximal to the wedge top front edge 358. The apex width of each channel 662 is greater than the outlet width of the channel 662. Thus, the side walls of each channel 662 are angled toward the channel outlet 664. Water migrating down the sloped surface of the wedge top side 321 is directed by the side walls of the channels 662 to the channel outlets 564 and into the respective weep tube 669.
At least of a portion of each weep tube 669 is disposed on the wedge top side 321. As shown in
A waterproof membrane 322 is disposed on the wedge top side 321. The waterproof membrane 322 covers the wedge top side 321 and extends between the wedge top rear edge 356 to the wedge top front edge 358 and between the wedge first side 357 to the wedge second side 353. A plurality of channels is aligned on the wedge top side 321. Each channel 762 of the plurality of channels is bounded by the waterproof membrane 322, which forms the floor of each channel 762, a first water-resistant ribbon 766, and a second water-resistant ribbon 768. Each of the first water-resistant ribbon 766 and the second water-resistant ribbon 768 of each channel 762 forms a sidewall of the channel 762. Each first ribbon 766 of each channel 762 extends from a first water-resistant ribbon end 772 disposed at the wedge top front edge 358 to a first water-resistant ribbon apex 770 disposed intermediate between the wedge top rear edge 356 and the wedge top front edge 358. Each second ribbon 768 of each channel 762 extends from a second water-resistant ribbon end 771 disposed at the wedge top front edge 358 to a second water-resistant ribbon apex 770 disposed intermediate between the wedge top rear edge 356 and the wedge top front edge 358. Each first ribbon end 772 of each channel 762 is spaced apart from each second ribbon end 771 of the channel 762, thereby forming a channel outlet 764 therebetween. Each first ribbon 766 and each second ribbon end 768 of each channel 762 is arcuate. Each first water-resistant ribbon apex 770 of each channel 762 is spaced apart from each second water-resistant ribbon apex 770 of the channel 762. The first and second apexes 770 of each channel 762 are spaced farther apart than the first and second ribbon ends 772 of the channel 762. Each channel 762 has an apex width proximal to the wedge top rear edge 356 and an outlet width proximal to the wedge top front edge 358. The apex width of each channel 762 is greater than the outlet width of the channel 762. Thus, the side walls of each channel 762 are concave and approach the opposing side wall and curved toward the channel outlet 764. Water migrating down the sloped surface of the wedge top side 321 is directed by the side walls of the channels 762 to the channel outlets 764.
A waterproof membrane 322 is disposed on the wedge top side 321. The waterproof membrane 322 covers the wedge top side 321 and extends between the wedge top rear edge 356 to the wedge top front edge 358 and between the wedge first side 357 to the wedge second side 353. A plurality of channels 862 is aligned on the wedge top side 321. Each channel 862 of the plurality of channels is bounded by the waterproof membrane 322, which forms the floor of each channel 862, a first water-resistant ribbon 866, and a second water-resistant ribbon 868. Each of the first water-resistant ribbon 866 and the second water-resistant ribbon 868 of each channel 862 forms a sidewall of the channel 862. Each first ribbon 866 of each channel 862 extends from a first water-resistant ribbon end 872 disposed intermediate between the wedge top front edge 358 and the wedge top rear edge 356 to a first water-resistant ribbon apex 870 also disposed intermediate between the wedge top rear edge 356 and the wedge top front edge 358. Each second ribbon 868 of each channel 862 extends from a second water-resistant ribbon end 871 disposed intermediate between the wedge top rear edge 356 and the wedge top front edge 358 to a second water-resistant ribbon apex 870 disposed intermediate between the wedge top rear edge 356 and the wedge top front edge 358. Each first ribbon end 872 of each channel 862 is spaced apart from each second ribbon end 871 of the channel 862, thereby forming a channel outlet therebetween at the open top end 877 of a weep tube 869. Each first ribbon 866 of each channel 762 is arcuate and opposes the second water-resistant ribbon 868 of the respective channel 862. Accordingly, each first water-resistant ribbon apex 870 of each channel 862 is spaced apart from each second water-resistant ribbon apex 870 of the channel 862. The first and second apexes 870 of each channel 862 are spaced farther apart than the first and second ribbon ends 871 of the channel 862. Each channel 862 has an apex width proximal to the wedge top rear edge 356 and an outlet width proximal to the wedge top front edge 358. The apex width of each channel 862 is greater than the outlet width of the channel 862. Thus, the side walls of each channel 862 are concave and approach the opposing side wall and curved toward the channel outlet 864. Water migrating down the sloped surface of the wedge top side 321 is directed by the side walls of the channels 862 to the channel outlets at the open top ends 877 and into the respective weep tubes 869. The water can travel through the hollow weep tube 869 to the open bottom end 873 and out of the wall assembly.
The rear side 949 and the top side 921 cooperate to form a top rear edge 956. The front side 959 and the top side 921 cooperate to form a top front edge 958. The rear side 949 and the top side 921 intersect at the top rear edge 956 and cooperate to form a rear top angle 961. The front side 959 and the top side 921 intersect at the top front edge 958 and cooperate to form a front top angle 957. The rear top angle 961 is acute and less than 90°. The front top angle 957 is obtuse and greater than 90°. The front side 959 of the fireblocking base form 906 can exhibit a height sufficiently tall enough to meet applicable regulations and/or ordinances on fireblocking minimum heights while also providing the inclined top side 921 that allows for water to move downward there along. Alternatively, the fireblocking base form 906 can be composed of a rectangular fireblocking base form, such as 306, shown in
The fireblocking base form 906 comprises a fire-resistant material 975, such as, for example, mineral wool, rock wool, foamed concrete, cementitious material, or glass matting. Examples of fire-resistant material include THERMAFIBER® Mineral Wool CI-C SC18 Mineral Wool Insulation from Thermafiber, Inc. of Toledo, Ohio, USA, and the monolithic density version of FRONTROCK™ Stone Wool Insulation from ROCKWOOL® of Milton, Ontario, Canada. The fireblocking base form 906 comprises a lamella 947 of the fire-resistant material 975. The lamella 947 comprises a plurality of lamellar layers 973 stacked upon each other to form the overall lamella 947. The lamellar layers 973 are aligned generally perpendicular or transverse to the front side 959 and generally parallel to the bottom side 955 of the fireblocking base form 906. In one aspect, the fireblocking base form 906 can comprise the fire-resistant material 975. In another aspect, the fireblocking base form 906 can consist essentially of the fire-resistant material 975. In yet another aspect, the fireblocking base form 906 can consist of the fire-resistant material 975. In one aspect, the fireblocking base form 906 can comprise a lamella 947 of fire-resistant material 975. In another aspect, the fireblocking base form 906 can consist essentially of a lamella 947 of fire-resistant material 975. In a further aspect, the fireblocking base form 906 can consist of a lamella 947 of fire-resistant material 975.
A waterproof membrane 922 is disposed on the top side 921. The waterproof membrane 922 covers the top side 921 and extends between the top rear edge 956 to the top front edge 958 and between the first side 957 to the second side 953. A plurality of channels 962 is aligned on the top side 921. Each channel 962 of the plurality of channels is bounded by the waterproof membrane 922, which forms the floor of each channel 962, a first water-resistant ribbon 966, and a second water-resistant ribbon 968. Each of the first water-resistant ribbon 966 and the second water-resistant ribbon 968 of each channel 962 forms a sidewall of the channel 962. Each first ribbon 966 of each channel 962 extends from a first water-resistant ribbon end 972 disposed at the wedge top front edge 958 to a first water-resistant ribbon apex 970 disposed at the wedge top rear edge 956. Each second ribbon 968 of each channel 962 extends from a second water-resistant ribbon end 971 disposed at the wedge top front edge 958 to a second water-resistant ribbon apex 970 disposed at the wedge top rear edge 956. Each first ribbon end 972 of each channel 962 is spaced apart from each second ribbon end 971 of the channel 962, thereby forming a channel outlet 964 therebetween. Each first ribbon 966 of each channel 962 is disposed at an angle and oblique to the second water-resistant ribbon 968 of the respective channel 962. Accordingly, each first water-resistant ribbon apex 970 of each channel 962 is spaced apart from each second water-resistant ribbon apex 970 of the channel 962. The first and second apexes 970 of each channel 962 are spaced farther apart than the first and second ribbon ends 972 of the channel 962. Each channel 962 has an apex width proximal to the wedge top rear edge 956 and an outlet width proximal to the wedge top front edge 958. The apex width of each channel 962 is greater than the outlet width of the channel 962. Thus, the side walls of each channel 962 are angled toward the channel outlet 964. Water migrating down the sloped surface of the wedge top side 921 is directed by the side walls of the channels 962 to the channel outlets 964.
The insulation layer 350 is aligned above the fireblocking base form 406 in the exterior wall system assembly 900. A water-resistant layer 323 is applied to the substrate 315, and vertical ribbons of an adhesive layer 325 are disposed on the water-resistant layer 323. The insulation layer 350 is mounted to the substrate 315 by adherence provided by the vertical ribbons of the adhesive layer 325. The bottom side 378 is cut at an angle so that the front bottom edge of the insulation layer 350 is lower than the rear bottom edge of thereof. The angle of the bottom side 378 of the adhesive layer is generally equal to the angle of the wedge top side 921. An arcuate channel 377 is formed in the bottom side 378 and extends from the rear bottom edge to the front bottom edge of the insulation layer 350. The arcuate channel 377 is aligned with the channel outlet 964 of the channel 962 with which the arcuate channel 377 cooperates. The weep hole 340 is the front end of the arcuate channel 377. The arcuate channel 377 provides a portion of a ceiling for the channel 962 for water migrating through a channel 962 to the front face of the exterior wall system assembly 900.
In one aspect, each fireblocking row 266 of fireblocking base forms 906 can be aligned a distance in a range of about 2.438 m to about 6.096 m from the nearest adjacent fireblocking row 266 of fireblocking base forms 906 above and/or below. In another aspect, each fireblocking row 266 of fireblocking base forms 906 can be aligned a distance in a range of about 3 m to about 6 m from the nearest adjacent fireblocking rows 266 of fireblocking base forms 906 above and/or below. In a further aspect, each fireblocking row 266 of fireblocking base forms 906 can be aligned a distance of less than or equal to about 6 m from the nearest adjacent fireblocking rows 266 of fireblocking base forms 906 above or below. In yet another aspect, each fireblocking column 306 can be aligned a distance in a range of about 2.438 m to about 6.096 m from the nearest adjacent fireblocking columns 306 to the left and/or right. In another aspect, each fireblocking column 306 can be aligned a distance in a range of about 3 m to about 6 m from the nearest adjacent fireblocking columns 306 to the left and/or right. In a further aspect, each fireblocking column 306 can be aligned a distance of less than or equal to about 6 m from the nearest adjacent fireblocking columns 306 to the left and/or right. In still a further aspect, the exterior wall system assembly 300 can comprise one or more concealed spaces each with an area bounded by one or more fireblocking columns 306 and one or more fireblocking base forms 906 of less than about 9.3 m2. In another aspect, the exterior wall system assembly 300 can comprise one or more concealed spaces each which is disposed within an area 303 bounded by one or more fireblocking columns 306 and one or more fireblocking base forms 906 in a range of about 4 m2 to about 9 m2.
The fireblocking base form 1260 is aligned adjacent to the floor slab 1403 of the building on which the exterior wall system assembly 1400 is mounted. The fireblocking base form 1260 can be aligned within the wall assembly such that the top side 1252 is disposed anterior to the top of the floor slab 1403. A water-resistant coating layer 1412 is disposed on the fireblocking base form 1260. The water-resistant coating layer 1412 covers the front side 1259, the top side 1252, the bottom side 1255, and the rear side 1249 of the fireblocking base form 1260 and acts as a waterproof membrane that can serve as either the floor or a subfloor, with a waterproof conformable membrane 1414 disposed thereon and acting as the floor, of a plurality of channels disposed on the tops side 1252. Each of the plurality of channels disposed on the top side 1252 are formed by a plurality of ribbons, such as second ribbon 1468, that form the sidewalls of each channel. Each channel of the plurality of channels is in fluid communication with the trough 1438 and concealed spaces 1480 vertically aligned within the wall assembly 1400. Each channel of the plurality of channels has an outlet disposed at the open top end of a weep tube 1448, a portion of which is disposed on the top side 1252 of the fireblocking base form 1260. Each weep tube 1448 is hollow and open at a bottom end 1440 thereof, which is in fluid communication with the outer face 1410 of the wall assembly 1400.
In one aspect, the water-resistant coating layer 1412 can cover the left side 1251 and/or the right side 1253 of the fireblocking base form 1260. In another aspect, the left side 1251 and/or the right side 1253 of the fireblocking base form 1260 are uncovered by a water-resistant coating layer 1412. A first mesh layer 1408 is disposed on the fireblocking base form 1260. The first mesh layer 1408 can be embedded in the water-resistant coating layer 1412 and cover the front side 1259, the top side 1252, the rear side 1249, and the bottom side 1255 of the fireblocking base form 1260. In one aspect, the first mesh layer 1408 can cover the left side 1251 and/or the right side 1253 of the fireblocking base form 1260. In another aspect, the left side 1251 and/or the right side 1253 of the fireblocking base form 1260 are uncovered by a first mesh layer 1408. The fireblocking base form 1260 can function as a barrier to the propagation of fire and hot gasses through the air cavities and/or other internal void spaces of the exterior wall system assembly 1400 from one story to another.
The exterior wall system assembly 1400 also includes insulation layers 1462 disposed above and below the fireblocking base form 1260. The insulation layers 1462 can be formed of any appropriate material, such as expanded polystyrene (EPS), extruded polystyrene (XPS), graphite polystyrene (GPS), rock wool, and/or mineral wool or another material having insulative properties and other desired performance characteristics. The insulation layer 1462 is mounted to the sheathing layer 1401 by an adhesive layer 1432. The adhesive layer 1432 can be provided in a plurality of vertical strips on the air and water-resistant barrier layer 1422. One or more concealed spaces 1480 can be formed by the cooperation of the adhesive layer 1432, the air and water-resistant barrier layer 1422 and the insulation layer 1462. These concealed spaces 1480 potentially could serve as a route through which fire could propagate vertically and/or horizontally through the exterior wall system assembly 1400. The insulation layer 1462 mounted above the fireblocking base form 1260 includes a beveled bottom side that is aligned generally parallel to the top side 1252 of the fireblocking base form 1260. The beveled bottom side of the upper insulation layer 1462 is spaced apart from the top side 1252 of the fireblocking base form 1260. The upper insulation layer 1462 also includes a trough 1438 disposed along the rear bottom portion of the upper insulation layer between the beveled bottom side and the rear face of the upper insulation layer 1462. The trough 1438 is aligned generally above the rear upper portion of the top side 1252 and the top rear edge 1256 of the fireblocking base form 1260. Both the beveled bottom side and the trough 1438 can extend the entire width of the upper insulation layer 1462. The trough 1438 can serve as a collection area for water or moisture that drains down the internal surfaces of the exterior wall system assembly 1400.
An air and water-resistant barrier layer 1422 is disposed on the sheathing layer 1401 and the floor slab 1403. The air and water-resistant barrier layer 1422 is disposed between the insulation layer 1462 and the sheathing layer 1401. Also, the air and water-resistant barrier layer 1422 is disposed between the fireblocking base form 1260 and both the sheathing layer 1401 and the floor slab 1403. The fireblocking base form 1260 is mounted to air and water-resistant barrier layer 1422 by a waterproof adhesive 1409. The fireblocking base form 1260 can be installed by applying a full bed of water-resistant adhesive 1409 to the back side 1249. The fireblocking base form 1260 can then be placed at the designated location on the wall surface using firm, uniform pressure by hand or with a straight edge across the entire surface of the fireblocking base form 1260 to force the water-resistant adhesive 1409 into intimate contact with the substrate, such that no void space is left between the back of the fireblocking base form 1260 and the substrate to which it has been applied.
A waterproof conformable membrane 1414 is disposed on the air and water-resistant barrier layer 1422 and angled down to cover at least a portion of the top side 1252 of the fireblocking base form 1260. The waterproof conformable membrane 1414 is separated from direct contact with the top side 1252 of the fireblocking base form 1260 by the water-resistant coating layer 1412 and the first mesh layer 1408. The waterproof conformable membrane 1414 can cooperate with the air and water-resistant layer 1422 and the waterproof coating layer 1412 to form a waterproof barrier through which water and moisture cannot penetrate and a pathway by which water and moisture that accumulates in the void space within the exterior wall system assembly 1400 can be directed from the interior of the exterior wall system assembly 1400 down and along the top side 1252 of the fireblocking base form 1260.
The exterior wall system assembly 1400 also comprises an outer finish layer 1405 mounted at the outer face 1410. The outer finish layer 1405 covers a majority of the outer face 1410 of the exterior wall system assembly 1400. The outer finish layer 1405 is disposed on a base coat layer 1407. A second mesh layer 1408 is embedded in the base coat layer 1407. The outer finish layer 1405, the base coat layer 1407 and the second mesh layer 1408 are mounted on both the insulation layers 1462 and the fireblocking base form 1260. A backer rod 1425 is disposed below the fireblocking base form 1260 and above a lower insulation layer 1462. A sealant layer 1426 is disposed between the backer rod 1425 and the outer face 1410 of the exterior wall system assembly 1410. The finish layer 1405 can be selected from stucco, opaque glass, fiber cement, resin cast brick veneer, resin cast stone veneer, resin cast tile veneer, terracotta, decorative laminate, thin masonry brick veneer, thin masonry stone veneer, or thin masonry tile veneer.
A plurality of weep tubes 1448 is aligned on the top side 1252 of the fireblocking base form 1260. A plurality of channels is also formed on the fireblocking base form 1260. The plurality of channels can be configured according to any configuration as shown in
Mounted to the structure wall frame 1520 is an insulation layer 1527. The insulation layer 1527 can comprise a mineral wool. Disposed between sections of the insulation layer 1527 is a fireblocking base form 1560. The fireblocking base form 1560 comprises an angled top side 1552 that is sloped downward from the rear side to the front side of the fireblocking base form 1560. An upper section of the insulation layer 1527 can have a beveled bottom side that is aligned generally parallel to the top side 1552 of the fireblocking base form 1560. In one aspect, the beveled bottom side of the upper insulation layer 1527 can contact the top side 1552 of the fireblocking base form 1560. The fireblocking base form 1560 comprises a lamella 1571 that includes lamellar layers of fire-resistant material 1275. The lamellar layers of the lamella 1571 are aligned generally perpendicular to the outer face 1510 of the exterior wall system assembly 1500. Portions of the T-rails 1518 project beyond the outer surfaces of the insulation layer 1527. The cross-bar of each T-rail 1518 is aligned generally parallel to the outer surface of the insulation layer 1527 and spaced apart therefrom, with the outer surface of the insulation layer 1527 aligned proximal to the structural wall frame 1502 and the cross-bar of each T-rail 1518 aligned distal to the structural wall frame 1502.
The exterior wall system assembly 1500 also comprises a carrier board 1506 mounted on the outer side of the crossbar of each T-rail 1518. A base coating layer 1512 is applied to the outer surface of the carrier board 1506 and a mesh layer 1508 is disposed on the base coating layer 1512. A primer coating layer 1507 can be disposed on the mesh layer 1508 and the base coating layer 1512. A finish layer 1505 is disposed on the primer coating layer 1507 and is disposed at the outer face 1510 of the exterior wall system assembly 1500.
The front side of the insulation layer 1527 is spaced apart from the crossbars of the T-rails 1518 and the rear side of the carrier board 1506, thereby forming concealed spaces 1580 within the exterior wall system assembly 1500. The depth of the fireblocking base form 1560 is greater than the depth of the insulation layer 1527. Accordingly, the fireblocking base form 1560 projects beyond the front side of the insulation layer 1527 to the back side of the cladding or face layer. The fireblocking base form 1560 can bound one or more concealed spaces 1580 within the exterior wall system assembly 1500.
A plurality of weep tubes 1548 are disposed on the top side 1552 of the fireblocking base form 1560. A plurality of channels is also formed on the fireblocking base form 1560. The plurality of channels can be configured according to any one of the channel configurations shown in
As shown in
A lower portion of the panel body 1102 is shown in
As shown in
Attached to the support frame 1125 is a base layer 1126. The base layer 1126 can be formed of gypsum and glass matting. The base layer 1126 provides a substrate extending across the length and width of the panel to provide a surface to which the other panel layers can be affixed. A waterproof membrane 1128 is disposed on the base layer 1126. The waterproof membrane 1128 can be formed of a latex-based coating, such as STO GOLD COAT® membrane coating, manufactured by Sto Corp of Atlanta, Georgia, USA, or other coating providing water-resistant performance characteristics. The waterproof membrane 1128 can serve to prevent moisture and air penetration of the base layer 1126. In the panel body 1102, adhesive ribbon 1132 can be applied to the base layer or water-resistive barrier layer. The adhesive ribbon 1132 can be formed of any appropriately performing adhesive and serves as a means for attaching the insulation layer 1162 to the base layer 1126. As shown in
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The trough 1138 is in fluid communication with concealed spaces 1180 within the panel body 1102 disposed between the insulation layer 1162 and the base layer 1126. These concealed spaces 1180 can be approximately the depth of the adhesive ribbon and extend across the panel between each adhesive ribbon. In the panel body 1102 shown in
As can be seen in
As shown in
The panel bodies 1102 can be affixed in place on the structure and then an air/water-resistive barrier caulking can be applied to the seams formed between the panel bodies 1102. In this way, the exterior wall panel system 1100 including a plurality of panel bodies 1102 can be arranged to form a generally continuous exterior surface of a building or other structure. As so installed, the exterior wall panel system 1100 allows for water that penetrates the interior of the wall structure to be channeled out of the wall through the openings 140 formed in the exterior layers of each panel body 1102.
The panels 1102 of the exterior wall panel system 1100 can comprise more than one fireblocking row 1182 of fireblocking base forms 1160, more than one row of weep holes 1140, and/or more than two fireblocking columns 1183 of fireblocking vertical forms 1163 within a single panel body. If the dimensions of a particular panel 1102 is greater than the maximum allowable distances between fireblocking rows 1182 and/or fireblocking columns 1183, then the panel 1102 can be constructed to include one or more additional fireblocking rows 1182 of fireblocking base forms 1160 and/or one or more additional fireblocking columns 1183 of fireblocking vertical forms 1163 that are aligned horizontally intermediate between the bottom most fireblocking base form 1163 of the fireblocking top form 166 and vertically between the left fireblocking vertical form 1163 and the right fireblocking vertical form 1163.
A plurality of weep tubes 1448 is aligned on the top side 1352 of the fireblocking base form 1360. A plurality of channels is also formed on the fireblocking base form 1360. The plurality of channels can be configured according to any configuration as shown in
The fireblocking base form 1360 is aligned adjacent to the floor slab 1403 of the building on which the exterior wall system assembly 1400 is mounted. The top side 1352 of the fireblocking base form 1360 is aligned anterior and superior to the top surface of the adjacent floor slab 1403, and the bottom side 1355 is aligned anterior and inferior to the bottom surface of the adjacent floor slab 1403. The fireblocking base form 1360 creates a horizontally aligned fireblocking layer that separates the concealed spaces within one story of the wall assembly 1400 from the concealed spaces of within the adjacent story of the wall assembly 1400 directly above or below. The fireblocking base form 1360 can be provided with a total height sufficient to meet the applicable building code requirements for a fireblocking layer.
The fireblocking top form 1660 of the exterior wall system assembly 1600 comprises a fire-resistant material, such as, for example, mineral wool or rock wool that is provided in a plurality of lamellar layers to form a lamella 1671. The lamellar layers of the lamella 1671 are aligned generally perpendicular to an outer face 1610 of the exterior wall system assembly 1600.
A waterproof coating layer 1607 is disposed on the fireblocking top form 1660. The waterproof coating layer 1607 covers the front side and the top side of the fireblocking top form 1660. A mesh layer 1608 is disposed on the fireblocking top form 1660. The first mesh layer 1608 can be imbedded in the waterproof coating layer 1607 and cover the front side and the top side of the fireblocking top form 1660. The fireblocking top form 1660 can function as a barrier to the propagation of fire and hot gasses through the concealed spaces of the exterior wall system assembly 1600 from one story to another.
The exterior wall system assembly 1600 also comprises an insulation layer 1662 disposed directly below and above the fireblocking top form 1660. The portion of the insulation layer 1662 disposed directly below the fireblocking top form 1660 can be aligned adjacent to and in direct contact with the bottom side of the fireblocking top form 1660. The portion of the insulation layer 1662 disposed directly above the fireblocking top form 1660 is spaced apart from the fireblocking top form 1660. The fireblocking top form 1660 can cooperate with the insulation layer 1662 to form a continuous layer that exhibits both an insulative and fireblocking characteristics.
The insulation layer 1662 can be formed of the same fire-resistant material as the fireblocking top form 1660, such as rock wool or mineral wool. The fire-resistant material of the insulation layer 1662 can be provided in a plurality of lamellar layers that form a lamella 1671. Alternatively, the insulation layer 1662 can be formed of expanded polystyrene, extruded polystyrene, and/or graphite polystyrene. The insulation layer 1662 is mounted to the adjacent sheathing layer 1630 by an adhesive layer 1632. The adhesive layer 1632 can be provided in a plurality of vertical strips on the air and water-resistant barrier layer 1622. The plurality of vertical strips of adhesive layer 1632 can be applied to the rear side of the insulation layer 1662, and the insulation layer 11662 can then be placed in a horizontal running bond pattern on the sheathing layer 630 with joints of the insulation layer 1662 components tightly abutted. Firm, uniform pressure by hand or with a straight edge can be applied across the entire surface of the insulation layer 1662 thereby adhering it to the sheathing layer 1630. One or more concealed spaces 1680 can be formed by the cooperation of the strips of adhesive layer 1632, the air and water-resistant barrier layer 1622 and the insulation layer 1662. These concealed spaces 1680 potentially can serve as a route through which fire can propagate vertically and/or horizontally through the exterior wall system assembly 1600. The insulation layer 1662 mounted above the fireblocking top form 1660.
An air and water-resistant barrier layer 1622 is disposed on the sheathing layer 1630. The air and water-resistant barrier layer 1622 is disposed between the insulation layer 1662 and the sheathing layer 1630. The air and water-resistant barrier layer 1622 also is disposed between the fireblocking top form 1660 and the sheathing layer 1630. The fireblocking top form 1660 is mounted to air and water-resistant barrier layer 1622 by a full, continuous layer of waterproof adhesive 1609.
A waterproof conformable membrane 1614 is disposed on the air and water-resistant barrier layer 1622 and angled down to cover at least a portion of the top side 1652 of the fireblocking top form 1660. The waterproof conformable membrane 1614 extends downward across a horizontally aligned gap between the vertically aligned sections of the sheathing layer 1630. The waterproof conformable membrane 1614 is separated from direct contact with the top side 1652 of the fireblocking top form 1660 by a waterproof coating layer 1607 and a mesh layer 1608. The waterproof conformable membrane 1614 can cooperate with the air and water-resistant layer 1622 and the waterproof coating layer 1607 to form a waterproof barrier through which water and moisture cannot penetrate and a pathway by which water and moisture that accumulates in the void space within the exterior wall system assembly 1600 can be directed from the interior of the exterior wall system assembly 1600 down and along the top side 1652 of the fireblocking top form 1660.
A horizontally aligned gap extends between the sloped top side 1652 of the fireblocking top form 1660 and the bottom side of the insulation layer 1662 aligned directly above the fireblocking top form 1660. Moisture can drain into this gap from the concealed space 1680 aligned between the upper insulation layer 1662 and the air and water-resistant layer 1622 and the sheathing layer 1630. The waterproof conformable membrane 1614 can prevent moisture from moving inward into the gap formed between sections of the sheathing layer 1630 and can assist in directing water down onto the top side 1652 of the fireblocking top form 1660.
A plurality of channels and a plurality of weep tubes 1648 are aligned on the top side 1652 of the fireblocking top form 1660. The plurality of channels can be configured according to the configuration of any channel shown in
The exterior wall system assembly 1600 can comprises a plurality of concealed spaces each of which is bounded by the columns and rows of a fireblocking framework, not shown. The concealed spaces of the exterior wall system assembly 1600 are disposed in a bounded area that is bounded by at least one fireblocking top form 1660 and at least one fireblocking vertical form. In one aspect, a bounded area can be bounded by two fireblocking rows of fireblocking top forms 1660 and two fireblocking columns of fireblocking vertical forms that intersect the two fireblocking rows. The fireblocking framework can comprise a plurality of fireblocking columns that extend upward along the height of a multi-story building and a plurality of fireblocking rows of fireblocking top forms 1660 extending along the width of the multi-story building and aligned along the floor slab or base of each story. Each of the plurality of fireblocking rows of fireblocking top forms 1660 intersect the plurality of fireblocking columns. Each fireblocking column can comprise one or more fireblocking vertical forms aligned end-to-end within the exterior wall system assembly 1600. Each fireblocking vertical form can comprise a lamella 1671 of lamellar layers of fire-resistant material, such as rock wool or mineral wool, aligned generally perpendicular or transverse to the outer face of the exterior wall system assembly 1600. The fireblocking vertical forms can cooperate with the fireblocking top forms 1660 and the insulation layers 1662 to form a substantially continuous layer of insulation across a majority of the wall formed by the exterior wall system assembly 1600.
The exterior wall system assembly 1600 also can comprise one or more weep hole rows, each of which comprises a plurality of weep holes. The weep hole rows are aligned proximal to the fireblocking top forms 1660 and extend through the horizontally aligned rows of sealant 1678. Each fireblocking top form 1660 can abut at least one fireblocking vertical form on the left side and/or the right side of the fireblocking base form 1660. Likewise, each fireblocking vertical form can abut at least one fireblocking top form 1660 on the left side and/or the right side of the fireblocking vertical form. The fire-resistant material of each fireblocking vertical form contacts the fire-resistant material of each adjacently aligned fireblocking top form 1660 and each adjacently aligned fireblocking vertical form contacting the respective fireblocking vertical form, thereby forming the fireblocking framework that forms a continuous multi-layer fire-resistant barrier between and throughout each story of the multi-story building. Each fireblocking vertical form can be mounted to the sheathing layer 1630 by a full layer of water-resistant adhesive 1609, thereby creating a firebreak between each of the areas of concealed space.
Attached to the support frame 1125 is a base layer 1126. The base layer 1126 can be formed of gypsum and glass matting. The base layer 1126 provides a substrate extending across the length and width of the panel to provide a surface to which the other panel layers can be affixed. A waterproof membrane 1128 is disposed on the base layer 1126. The waterproof membrane 1128 can be formed of a latex-based coating, such as STO GOLD COAT®, manufactured by Sto Corp, or other coating providing waterproof performance characteristics. The waterproof membrane 1128 can serve to prevent moisture and air penetration of the base layer 1126. In the exterior wall panel 1702, vertical strips of adhesive ribbon 1132 can be applied to the waterproof membrane 1128. The adhesive ribbon 1132 can be formed of any appropriately performing adhesive and serves as a means for attaching the insulation layer 1162 to the base layer 1126.
The insulation layer 1162 extends across a central portion of the width of the exterior wall panel 1702. The insulation layer 1162 can be formed of any appropriate material, such as expanded polystyrene (EPS), extruded polystyrene (XPS), graphite polystyrene (GPS), rock wool and/or mineral wool having insulative properties and other desired performance characteristics. The insulation layer 1162 can comprise a continuous board that is sized and shaped to fit within the exterior wall panel 1702.
The fireblocking base form 1766 is disposed in the exterior wall panel 1702 between the base 1130, the insulation layer 1162, the left fireblocking vertical form 1163, and the right fireblocking vertical form 1165. The fireblocking base form 1766 is rectangular and abuts both the left fireblocking vertical form 1163, and the right fireblocking vertical form 1165. The fireblocking base form 1766 extends across a lower center portion of the width of the exterior wall panel 1702. The fireblocking base form 1766 is formed of a fire-resistant material 1275, such as mineral wool or rock wool that is provided in a plurality of lamellar layers, thereby forming a fire-resistant lamella. The fireblocking base form 1766 can be of various sizes and configurations.
The exterior wall panel 1702 of the exterior wall panel system 1700 optionally can include edge wraps 1176 disposed on the edges of the panel body. The edge wraps can include one or more layers that provide the desired performance characteristics. For example, the edge wrap 1176 can include a joint reinforcement, a mesh substrate, and/or a water air barrier membrane. The edge wrap 1176 can extend across the entire edge of the exterior wall panel 1702 or a portion thereof. For example, the edge wrap 1176 can extend from behind the exterior layer 1112 along the second side edge 1134 to the support frame 1125. A first edge wrap can be disposed on a first side edge of a panel and a second edge wrap can be disposed on a second side edge of the panel. Furthermore, the edge wrapping can extend over all or a portion of the top edge 1120 and/or the base 1130, so as to provide a barrier with desired performance features along all the edges of the panel.
The exterior wall panel system 1700 comprises a plurality of exterior wall panels 1702 that are mounted on a building in an arrangement similar to that of the exterior wall panel system 1100 shown in
The first water-resistant ribbons 366, 466, 566, 666, 766, 866, 966, and 1466 and the second water-resistant ribbons 368, 468, 568, 668, 768, 868, 868, and 1468 can comprise any water-resistant composition suitable for use in an exterior wall assembly and that can tend to inhibit or prevent penetration of water into the ribbon. The first water-resistant ribbons 366, 466, 566, 666, 766, 866, 966, and 1466 and the second water-resistant ribbons 368, 468, 568, 668, 768, 868, 868, and 1468 can comprise a caulk, sealant bead, tape, or other suitable material for forming the side walls of the channels. In one aspect, the first water-resistant ribbons 366, 466, 566, 666, 766, 866, 966, and 1466 and the second water-resistant ribbons 368, 468, 568, 668, 768, 868, 868, and 1468 can comprise a polymeric water-resistant composition. In another aspect, the polymeric water-resistant composition can comprise a silane polymer. In a further aspect, the polymeric water-resistant composition can comprise a calcium carbonate. In another aspect, the first water-resistant ribbons 366, 466, 566, 666, 766, 866, 966, and 1466 and the second water-resistant ribbons 368, 468, 568, 668, 768, 868, 868, and 1468 can comprise STO RAPIDGUARD® air-barrier and waterproofing material available from Sto Corp. of Atlanta, Georgia, USA.
The exterior wall system assemblies, the exterior wall system component subassemblies, and the exterior wall system components of the present disclosure can be of various heights, widths, and configurations. The fireblocking base forms, the fireblocking vertical forms, and the fireblocking frameworks of the exterior wall system assemblies, the exterior wall system component subassemblies, and the exterior wall system components herein have been described as comprising a fire-resistant material. In addition to rock wool, mineral wool, foamed concrete, cementitious materials, and glass matt faced gypsum sheathing or glass matt gypsum admixture, these fireblocking forms can be formed of any fire-resistant material and/or fireblocking material that complies with applicable laws, rules and ordinances for building structures and otherwise suitable for use in such exterior wall system assemblies, exterior wall system component subassemblies, and exterior wall system components and can be configured in rectangular shapes with flat surfaces horizontally aligned with the bottom surface or wedge shapes with a sloped top surface. The fireblocking base forms and fireblocking frameworks set forth herein can be used in wall assemblies of various construction, including masonry cavity wall assemblies.
The exterior wall system assemblies, the exterior wall system component subassemblies, and the exterior wall system components can be configured to comply with any one or more of NFPA® 285 Standard Fire Test Method For Evaluation Of Fire Propagation Of Exterior Wall Assemblies Containing Combustible Components; ASTM E330/E330M-14 (Reapproved 2021) Standard Test Method For Structural Performance Of Exterior Windows, Doors, Skylights And Curtain Walls By Uniform Static Air Pressure Difference; ASTM E2273-18 Standard Test Method For Determining The Drainage Efficiency Of Exterior Insulation And Finish Systems (EIFS) Clad Wall Assemblies; 2022 NYC Building Code Section 1408 Exterior Insulation And Finish Systems (EIFS); and, 2022 NYC Building Code Section 718.2.6.1 Exterior Wall Coverings Containing Plastics, Metal Composite Materials (MCM) Or High-Pressure Decorative Exterior-Grade Compact Laminates (HPL) Panels.
The embodiments set forth herein are provided to illustrate, not limit, the scope of the present disclosure. Alternative combinations and modifications of the features disclosed herein are contemplated by the present disclosure. Alternatives, variations, and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art are encompassed by the present disclosure.
This application claims priority to both U.S. Provisional Patent Application Ser. No. 63/547,006 entitled “Exterior Wall Assemblies and Exterior wall system assembly Components With Fireblocking And Drainage Features”, filed Nov. 2, 2023, and U.S. Provisional Patent Application Ser. No. 63/644,195, entitled “Exterior Wall System Assemblies, Exterior Wall System Component Subassemblies, And Exterior Wall System Components With Drainage Features”, filed May 8, 2024, both of which are hereby incorporated by reference in their entirety herein to provide continuity of disclosure.
| Number | Date | Country | |
|---|---|---|---|
| 63547006 | Nov 2023 | US | |
| 63644195 | May 2024 | US |
